Methods and systems for the formation and use of reduced weight building blocks forms

ABSTRACT

In some embodiments, a method may include preparing building forms including at least some cementitious materials. The method for preparing forms may include mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition. In some embodiment, at least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles. In some embodiments, the method may include mixing a second portion of water with the substantially dry composition for a second period of time to form a partially wet composition. In some embodiments, a method may include forming a building form including at least some cementitious materials from the partially wet composition. In some embodiments, the closed cell foam particles may include expanded polystyrene. In some embodiments, a ratio of the water to cementitious material particles may range from 0.20 to 0.40.

CLAIM OF PRIORITY

This application is a continuation of U.S. patent application Ser. No.14/561,956 entitled “METHODS AND SYSTEMS FOR THE FORMATION AND USE OFREDUCED WEIGHT BUILDING BLOCKS FORMS” filed on Dec. 5, 2014, whichclaims benefit of priority of U.S. Provisional Application Ser. No.61/986,829 entitled “METHODS AND SYSTEMS FOR THE FORMATION AND USE OFREDUCED WEIGHT BUILDING BLOCKS FORMS” filed Apr. 30, 2014, the contentsof all of which are incorporated by reference herein in their entiretyand for all purposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure generally relates to building forms. Moreparticularly, the disclosure generally relates to a method and systemfor making building forms including systems and methods formanufacturing building forms including at least some cementitiousmaterials.

2. Description of the Relevant Art

Recent innovations in cement-based construction materials have led toimproved durability, and overall quality. Building blocks and panelsmade of a mixture of polystyrene foam, cement, and other admixtures havecome into use. These composite building blocks can be stacked orotherwise arranged during construction in the same general manner asordinary cement blocks to form walls and other construction elements.Composite building blocks and panels can be shaped.

Because these composite building blocks and panels contain a significantproportion of polystyrene foam, they are lighter and easier to handleduring construction than pure concrete blocks of similar size. Becauseof their composition, such blocks and panels are easy to shape forinstallation of, for example, electrical wiring or plumbing. Suchcomposite blocks and panels have the additional advantage of providing agreater insulating value when compared with traditional buildingmaterials. The R-value of such blocks and panels is typically higherthan exhibited by buildings constructed of traditional buildingmaterials. In addition to R-value, the wall system provides thermalmass. The combination of continuous insulation, high R-value, andthermal mass give the energy efficiency performance of the wall system.Such composite blocks and panels are highly fire and pest resistant,dramatically reducing the risk of fire or pest damage to structures madewith them.

In a typical process for manufacturing such blocks and panels, varyingamounts of polystyrene foam and cement are mixed with chemicaladmixtures to hold the foam granules together in a lightweight compositemixture. The light-weight composite mixture is poured into a mold andcured in the mold until it has hardened enough to be handled by peopleor machinery.

SUMMARY

In some embodiments, a method may include preparing building formsincluding at least some cementitious materials. The method for preparingforms may include mixing substantially dry cementitious materialparticles with closed cell foam particles to form a substantially drycomposition. At least some of the cementitious material particles mayadhere to at least some surface deformations on the surface of theclosed cell foam particles. In some embodiments, the method may includemixing a second portion of water with the substantially dry compositionfor a second period of time to form a partially wet composition. In someembodiments, a method may include forming a building form including atleast some cementitious materials from the partially wet composition. Insome embodiments, the closed cell foam particles may include expandedpolystyrene. In some embodiments, the water to cementitious material byweight may range from 0.20 to 0.33 or from 0.20 to 0.40 by weight. Theresulting building form may include a reduced weight composite buildingform.

In some embodiments, the cementitious materials may include cement andfly ash.

In some embodiments, the closed cell foam particles may includepolystyrene. The closed cell foam particles may include expandedpolystyrene.

In some embodiments, a method may include containing the partially wetcomposition in a dispenser. The dispenser may form at least a portion ofa substantially automated building form production system. The methodmay further include mechanically transferring a first portion of thepartially wet composition from the dispenser to a mold coupled to thedispenser to form the first portion into a desired shape. The method mayinclude mechanically releasing the first portion of the partially wetcomposition from the mold. The method may include mechanicallytransferring a second portion of the partially wet composition from thedispenser to the mold to form the second portion into the desired shape.The method may include mechanically releasing the second portion of thepartially wet composition from the mold. The method may further includecuring the first portion and the second portion of the partially wetcomposition to form a building form including at least some cementitiousmaterials.

In some embodiments, the method may include mechanically transferringthe first portion of the partially wet composition from the dispenser toa conveyance container (e.g., a fill cart). The method may includemechanically transferring the first portion of the partially wetcomposition from the conveyance container to the mold.

In some embodiments, the method may include vibrating the conveyancecontainer while transferring the first portion (e.g., at between about35 Hz to 42 Hz or 35 Hz to 60 Hz (e.g., using machine settings)). Theconveyance container may be moved back and forth above the mold whiletransferring the first portion. The method may include screeding atleast some excess first portion above an upper level of the open moldusing the conveyance container.

In some embodiments, the method may include compressing the firstportion of the partially wet composition in the mold (e.g., to about60-90% of the first portions initial volume). The first portion of thepartially wet composition may be compressed in the mold using a tamperand/or a vibrator (e.g., between about 50 to 60 Hz (e.g., using machinesettings)). The first portion of the partially wet composition may becompressed for a period of time including, for example, between 1 to 20seconds, between 3 to 8 seconds, or between 4 to 6 seconds.

In some embodiments, mechanically releasing the first portion of thepartially wet composition from the mold comprises releasing the firstportion from the mold in less than 2 minutes, less than 1 minute, lessthan 30 seconds, or less than 10 seconds.

In some embodiments, vibration, within certain parameters during one ormore steps of the manufacturing process, of the mold, the partially wetcomposition, or both may be essential to automatically manufacturingbuilding forms in an efficient manner. In some embodiments, making thebuilding form may include vibration with a log-amplitude between a firstboundary and a second boundary. In some embodiments, the first and thesecond boundaries may be described as piecewise linear functionsconnecting the points. In some embodiments, the first boundary mayinclude a log-amplitude of about 200 mm/s at 0 Hz frequency, about 200mm/s at 20 Hz frequency, about 200 mm/s at 30 Hz frequency, about 25mm/s at 150 Hz frequency, about 2.0 mm/s at 350 Hz frequency, and about1.0 mm/s at 600 Hz frequency. The second boundary may include alog-amplitude of about 0.1 mm/s at 0 Hz frequency, about 0.1 mm/s at 20Hz frequency, about 5.0 mm/s at 50 Hz frequency, about 0.5 mm/s at 150Hz frequency, about 0.1 mm/s at 400 Hz frequency, and about 0.1 mm/s at600 Hz frequency (e.g., as described in methods).

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention may become apparent to those skilledin the art with the benefit of the following detailed description of thepreferred embodiments and upon reference to the accompanying drawings.

FIG. 1A depicts a diagram of a perspective view of an embodiment of abuilding form.

FIG. 1B depicts a diagram of an embodiment of a close-up detailed viewof an outer surface of the building form depicted in FIG. 1A. This ismerely one embodiment, in other embodiments closed cell foam particlesmay be more compacted together or more densely than depicted.

FIG. 1C depicts a diagram of a perspective view of an embodiment ofbuilding forms used to construct a portion of a wall of a building.

FIG. 2 depicts a flow chart of a method for preparing building formsincluding at least some cementitious materials.

FIG. 3 depicts a diagram of a perspective view of an embodiment of asystem for preparing building forms.

FIGS. 4A-B depict two tables (i.e., TABLE 4a and TABLE 4b) showingpoints along the upper and lower vibration boundaries for systems and/ormethods of preparing building forms.

FIG. 5 depicts a graphical representation of the operational vibrationboundaries for systems and/or methods of preparing building forms.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and may herein be described in detail. Thedrawings may not be to scale. It should be understood, however, that thedrawings and detailed description thereto are not intended to limit theinvention to the particular form disclosed, but on the contrary, theintention is to cover all modifications, equivalents and alternativesfalling within the spirit and scope of the present invention as definedby the appended claims.

The headings used herein are for organizational purposes only and arenot meant to be used to limit the scope of the description. As usedthroughout this application, the word “may” is used in a permissivesense (i.e., meaning having the potential to), rather than the mandatorysense (i.e., meaning must). The words “include,” “including,” and“includes” indicate open-ended relationships and therefore meanincluding, but not limited to. Similarly, the words “have,” “having,”and “has” also indicated open-ended relationships, and thus mean having,but not limited to. The terms “first,” “second,” “third,” and so forthas used herein are used as labels for nouns that they precede, and donot imply any type of ordering (e.g., spatial, temporal, logical, etc.)unless such an ordering is otherwise explicitly indicated. For example,a “third die electrically connected to the module substrate” does notpreclude scenarios in which a “fourth die electrically connected to themodule substrate” is connected prior to the third die, unless otherwisespecified. Similarly, a “second” feature does not require that a “first”feature be implemented prior to the “second” feature, unless otherwisespecified.

Various components may be described as “configured to” perform a task ortasks. In such contexts, “configured to” is a broad recitation generallymeaning “having structure that” performs the task or tasks duringoperation. As such, the component can be configured to perform the taskeven when the component is not currently performing that task (e.g., aset of electrical conductors may be configured to electrically connect amodule to another module, even when the two modules are not connected).In some contexts, “configured to” may be a broad recitation of structuregenerally meaning “having circuitry that” performs the task or tasksduring operation. As such, the component can be configured to performthe task even when the component is not currently on. In general, thecircuitry that forms the structure corresponding to “configured to” mayinclude hardware circuits.

Various components may be described as performing a task or tasks, forconvenience in the description. Such descriptions should be interpretedas including the phrase “configured to.” Reciting a component that isconfigured to perform one or more tasks is expressly intended not toinvoke 35 U.S.C. §112 paragraph (f), interpretation for that component.

The scope of the present disclosure includes any feature or combinationof features disclosed herein (either explicitly or implicitly), or anygeneralization thereof, whether or not it mitigates any or all of theproblems addressed herein. Accordingly, new claims may be formulatedduring prosecution of this application (or an application claimingpriority thereto) to any such combination of features. In particular,with reference to the appended claims, features from dependent claimsmay be combined with those of the independent claims and features fromrespective independent claims may be combined in any appropriate mannerand not merely in the specific combinations enumerated in the appendedclaims.

It is to be understood the present invention is not limited toparticular devices or methods, which may, of course, vary. It is also tobe understood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting. As used in this specification and the appended claims, thesingular forms “a”, “an”, and “the” include singular and pluralreferents unless the content clearly dictates otherwise. Thus, forexample, reference to “a form” includes one or more forms.

DETAILED DESCRIPTION Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art.

The term “cementitious materials” as used herein generally refers to anyof various building materials which may be mixed with a liquid, such aswater, to form a cement base substance, and to which an aggregate may beadded; includes cements, limes, and pozzolans.

The term “connected” as used herein generally refers to pieces which maybe joined or linked together.

The term “coupled” as used herein generally refers to pieces which maybe used operatively with each other, or joined or linked together, withor without one or more intervening members.

The term “directly” as used herein generally refers to one structure inphysical contact with another structure, or, when used in reference to aprocedure, means that one process effects another process or structurewithout the involvement of an intermediate step or component.

The term “piecewise linear function” as used herein generally refers toa function composed of straight-line sections.

In some embodiments, a system and/or a method may include preparingbuilding forms including at least some cementitious materials. FIGS.1A-B depict a diagram of a perspective view of an embodiment of abuilding form 100. In some embodiments, a building form may include alightweight material (for example lightweight relative to concretebuilding blocks (e.g., concrete masonry units (CMU)). In someembodiments, the building form may be formed from materials which arefire resistant, pest (e.g., termite, rodent, etc.) resistant, sounddampening, durable, provide increased safety from storm/wind damage,and/or provide a greater relative insulation value (e.g., relative toother common building materials). In some embodiments, building formsmay be formed from at least partially recycled materials. Building formsmay not be substantially structurally supportive (e.g., as regards thebuilding itself).

In some embodiments, building forms 100 may include a plurality ofchannels 110 formed within and/or along one or more edges 115 of thebuilding form. Channels or openings 110 a may extend through the body120 of the building form. Channels 110 b may extend along an edge of thebuilding form. Channels 110 b may have a shape equivalent to half of anopening 110 a cut along a longitudinal axis. When building forms 100 arestacked on top of one another and/or adjacent to one another along theiredges two channels 110 b positioned adjacent one another form an opening(e.g., similar to channels 110 b, although they do not have to have thesame cross section). Channels 110 may include any number of shape crosssections. Circular openings may include advantages such as inhibitingformation of air bubbles when the openings are filled with, for example,concrete or grout. In some embodiments, channels 110 may beapproximately 6″ in diameter. In some embodiments, channels 110 may bearranged in a grid approximately 16 inches on center. In someembodiments, the building form may be about 10 inches wide by about 16inches high by about 32 inches long.

FIG. 1C depicts a diagram of a perspective view of an embodiment ofbuilding forms 100 used to construct a portion of a wall 130 of abuilding. As depicted in FIG. 1C building forms 100 may be stacked atopone another such that channels 110 a from adjacent forms are alignedforming a channel which runs vertically (or alternatively horizontally)through the wall. Channels 110 b along edges 115 may form openings 110 bwhen building forms are positioned adjacent to one another. Oncepositioned the channels in the building form may form an interconnectingnetwork. Building forms may be positioned upon a suitably stablebuilding platform 140 (e.g., poured concrete slab foundation).Structurally supportive building materials 150 may be positioned inchannels 110 after the building forms are all positioned for a sectionof wall and/or as the building forms are positioned. Structuralmaterials may include, for example, metal columns or beams or rods(e.g., rebar) and/or concrete. Rebar may be positioned in one or more ofthe channels followed by concrete. The rebar/concrete may provide thestructural stability for the walls and building once positioned andcured. Typically, the structural materials are rebar and concrete. Insome cases, the concrete may be replaced with a structural ornon-structural grout. In some embodiments, the structural components maybe supplemented with a wide flange steel beam or column or with a steelpipe column. In such embodiments, the portions of the wall that areconcrete/rebar may be structurally tied to the areas of the walls thatare supplemented with steel columns or beams. Any number of types offacing may be applied to the exterior side (e.g., brick 160, stucco,siding, membranes, etc.) or interior side (e.g., wood or metal studs170, sheetrock 180, plaster, etc.) of the wall as required.

FIG. 2 depicts a flow chart of a method 200 for preparing building formsincluding at least some cementitious materials. The method for preparingforms may include mixing substantially dry cementitious materialparticles with closed cell foam particles to form a substantially drycomposition (210). At least some of the cementitious material particlesmay adhere to at least some surface deformations on the surface of theclosed cell foam particles.

In some embodiments, mixing substantially dry cementitious materialparticles with closed cell foam particles to form a substantially drycomposition may include combining the closed cell foam particles with afirst portion of substantially dry cementitious material particles toform a dry composition. In some embodiment, the first portion of thesubstantially dry cementitious material particles may include about 40to 60% of the substantially dry cementitious material particles of thetotal amount of particles to be added. The first portion may includeabout 50% or more of the total amount of particles to be added. Oncecombined the dry composition may be mixed or agitated in some way for afirst period of time. The first period of time may include about 10 to60 seconds, about 20 to 40 seconds or about 25 to 35 seconds. At leastsome of the cementitious material particles may adhere to at least somesurface deformations on the surface of the closed cell foam particles.Typically polystyrene is mixed with a wet cement mixture (wherein waterand cement have been mixed previously) or water, polystyrene, and cementare mixed together all at once. Mixing or agitating a portion of the drycementitious material particles with the closed cell foam particlesprior to adding water may allow the dry cementitious material particlesto adhere to the surface of the closed cell foam particles (for exampleto surface deformations on the closed cell foam particles). This maypromote better adhesion of the wet cementitious material upon mixingwater with the dry cementitious material particles and the closed cellfoam particles mixture relative to current methods. Premixing a portionof the dry cementitious material particles and the closed cell foamparticles may break up any clumps of the dry cementitious materialparticles before the water is added such that the amount of requiredcementitious material is reduced.

In some embodiments, the method may further include combining a firstportion of water with the dry composition to form the substantially drycomposition. In some embodiments, the first portion of water may includeabout 10 to 30% of the total amount of water to be added to make thesubstantially dry composition. The method may include combining thesubstantially dry composition with a second portion of substantially drycementitious material particles.

In some embodiments, the method may include mixing a second portion ofwater with the substantially dry composition (220) for a second periodof time to form a partially wet composition. The second period of timemay include about 50 to 100 or about 50 to 120 seconds, about 60 to 90seconds or about 70 to 80 seconds. In some embodiments, a ratio of thetotal water to the total cementitious material particles ranges from0.20 to 0.40, 0.20 to 0.33, 0.23 to 0.28, or 0.24 to 0.26 by weight. Insome embodiments, a ratio of the total water to the total cementitiousmaterial particles may range from 0.20 to 0.40 by weight. Typically ifthe ratio is less than 0.23 or greater than 0.28, then a manufacturedbuilding form may not be structurally sound (e.g., the building formonce removed from the mold may collapse before curing). For example, toolittle water and the partially wet composition will not stick togetherto make a building form when removed from a mold while substantiallyuncured in an automated process. If too much water then the partiallywet composition will collapse and not hold its shape when removed from amold while substantially uncured in an automated process. In someembodiments, a method may include forming a building form including atleast some cementitious materials from the partially wet composition(230).

In some embodiments, mixing the second portion of water with thesubstantially dry composition further comprises mixing at least oneadditive with the second portion of water and the substantially drycomposition. At least one of the additives may include plasticizers,super plasticizers, air entrainers, or viscosity modifiers. In someembodiments, additives may form less than 5% by weight. In someembodiments, using more additives is possible and should not affect theend product significantly; however, more additives may not be used dueto the associated costs.

Solid foams form a class of lightweight cellular engineering materials.Solid foams are classified into two types based on their pore structure:open cell foam structures and closed cell foam structures. Open cellfoam structures contain pores that are connected to each other and forman interconnected network that is relatively soft. Open cell foamstructures will fill with whatever they are exposed to, which may affectthe properties of the foam. Closed cell foam structures do not haveinterconnected pores. The closed cell foam structures normally havehigher compressive strength due to their structures. However,closed-cell foams are in general denser, require more material, and as aconsequence are more expensive to produce. The closed cells may befilled with a specialized gas to provide improved insulation. Theclosed-cell structure foams have higher dimensional stability, lowmoisture absorption coefficients, and higher strength compared to opencell foam structures.

In some embodiments, the closed cell foam particles may be formed atleast in part from homopolymers, copolymers, polyolefins,polycarbonates, polyesters, polyamides, natural rubbers, and syntheticrubbers. In some embodiments, the closed cell foam particles may beformed at least in part from polystyrene. In some embodiments, theclosed cell foam particles may include hexabromocyclododecane or otherbrominated compounds to, for example, provide additional fireresistance.

In some embodiments, closed cell foam particles may be formed from newor unrecycled polystyrene. In some embodiments, closed cell foamparticles may be formed at least partially from recycled polystyrene,which has been melted down and reformed into expanded polystyrene beads.Shredded polystyrene as is currently used in industry may cause problemsas opposed to “newly” expanded beads. Shredded polystyrene may producean inconsistent mix for the building form. One of the main issues withshredded polystyrene is the inconsistency of the raw material whichmakes it more difficult to manufacture the composite building form andalso results in very inconsistent product dimensions, density andoverall performance of the product. Newly expanded beads may be expandedto a desired size and/or desired shape in a uniform and consistentmanner.

In some embodiments, the closed cell foam particles may be formed atleast in part from expanded polystyrene. Polystyrene is extracted fromoil. Expanded polystyrene starts as small cylindrical or spherical beadswith a typical diameter of 0.5-1.5 mm. They may contain an expandingagent. In some embodiments, the expanded polystyrene beads may be formedfrom unexpanded beads with a mean unexpanded bead size of 0.50 mm to1.40 mm, 0.70 mm to 1.10 mm, or 0.80 mm to 0.90 mm. In some embodiments,the expanded polystyrene beads may be formed from unexpanded beads witha mean unexpanded bead size of 0.85 mm. Expanded polystyrene beads mayinclude a 1 mm to a 7 mm average diameter. Expanded polystyrene beadsmay include a 3.5 mm average diameter. Expanded polystyrene beads mayinclude a 0.005 g/cc to 0.025 g/cc bulk density (0.31 to 1.56 pcf).Expanded polystyrene beads may include a 0.008 g/cc to 0.016 g/cc bulkdensity (0.5 to 1.0 pcf). Unexpanded beads may be pushed duringexpansion resulting in particles with a lower density but with a brokensurface which is not smooth as standard beads are. Pushed beads may havesurface imperfections that may include wrinkles, dimples, and cracks.Pushed beads may be exposed to more steam and/or higher temperaturesand/or to longer dwell times during expansion which expands the beadbeyond its engineered specifications, thereby creating surfaceimperfections that may include wrinkles, dimples, and/or cracks.

Typically expanded polystyrene beads have a generally smooth texture.However, during the expansion process the beads may be over expanded(“pushed”) such that the surface of the bead wrinkles forming surfacedeformations including wrinkles, dimples, and cracks. In someembodiments, when dry particles are mixed with the over expandedpolystyrene beads the particles adhere to the surface deformations ofthe “wrinkled” particles.

Cementitious materials generally refers to any of various buildingmaterials which may be mixed with a liquid, such as water, to form acement based substance, and to which an aggregate may be added; includescements, limes, and pozzolans. In some embodiments, the cementitiousmaterials may include cement and fly ash. Fly ash (i.e., flue ash)generally refers to one of the residues generated in combustion. Fly ashmay include the fine particles that rise with flue gases. Ash which doesnot rise is generally referred to as bottom ash. In an industrialcontext, fly ash usually refers to ash produced during combustion ofcoal. Fly ash is generally captured by electrostatic precipitators orother particle filtration equipment before the flue gases reach thechimneys of coal-fired power plants. Fly ash when combined with bottomash removed from the bottom of the furnace is known as coal ash.Depending upon the source and makeup of the coal being burned, thecomponents of fly ash vary considerably, but typically fly ash includessilicon dioxide (SiO₂) (both amorphous and crystalline) and calciumoxide (CaO), both being endemic ingredients in many coal-bearing rockstrata. In some embodiments, cementitious materials may include Portlandcement, pozzolanic cements, gypsum cements, or silica cements. In someembodiments, cementitious materials may include Portland cement orpozzolanic cements.

In some embodiments, the building form includes a reduced weightcomposite building form.

In some embodiments, a system may produce a composite building form. Thesystem may function to manufacture composite building forms in asubstantially automatic or substantially “autonomous” fashion such thatonce the system is started up very little human interaction (except, forexample, through software based adjustments) is required during themanufacturing process. An automated mechanical process may significantlyreduce the financial costs associated with manufacturing the buildingforms. FIG. 3 depicts a diagram of a perspective view of an embodimentof a system 300 used for preparing building forms 100. In someembodiments, the system or method may include combining substantiallydry cementitious material particles with closed cell foam particles toform a substantially dry composition. The system may mix thesubstantially dry composition such that at least some of thecementitious material particles adhere to at least some surfacedeformations on the surface of the closed cell foam particles. Thesystem may mix water with the substantially dry composition to form apartially wet composition. In some embodiments, a mixer (not pictured)may be used to combine and mix the components together. A mixer may useany number of different agitation methods to mix the componentstogether.

In some embodiments, closed cell foam particles may be measured byweight (e.g., pounds) into a weigh dispenser using calibrated loadscales. Cement may be measured by weight (e.g., pounds) into a weighdispenser using calibrated load scales. Fly ash may be measured byweight (e.g., pounds) into a weigh dispenser using calibrated loadscales. Cement and fly ash may form at least a portion of a cementitiousmaterial. The same weigh dispenser may be used for the cement and thefly ash; however, the fly ash and cement may be measured individuallyand then summed. Water may be measured volumetrically or by weight.Additives, if employed, may be measured volumetrically. The additivesmay be pneumatically pumped into a measuring vessel.

In some embodiments, all of the weighed closed cell foam particles maybe dispensed into the mixer. A first portion (e.g., 50%) of the weigheddry cementitious material particles may be dispensed into the mixer. Thefirst portion and the closed cell foam particles may be mixed togetherfor period of time (e.g., 30 seconds). A first portion of the water(e.g., 25%) may be added to cementitious material particles and theclosed cell foam particles mixture. Remaining (e.g., 50%) weighed drycementitious material particles may be dispensed into the mixer. Theremaining water (e.g., 75%) of the water and any additives areintroduced to the mixer. The resulting mixture is then mixed for aperiod of time (e.g., 75 seconds). The resulting partially wetcementitious material may be transferred to a dispenser 310. In someembodiments, a conveyor may automatically transfer the partially wetcementitious material from the mixer to the dispenser 310. In someembodiments, the mixer may release the partially wet cementitiousmaterial through a discharge door automatically to the dispenser 310(e.g., dispenser 310 may be disposed below the mixer). The partially wetcementitious material may include 10 to 20% by volume cementitiousmaterial. The partially wet cementitious material may include 10 to 50%by volume cementitious material. The partially wet cementitious materialmay include 60 to 90% by volume closed cell foam particles. Thepartially wet cementitious material may include 50 to 90% by volumeclosed cell foam particles.

In some embodiments, the system or method may include mechanicallytransferring a first portion of the partially wet composition from thedispenser 310 to a mold 320 coupled to the dispenser to form the firstportion into a desired shape. In some embodiments, mechanicallytransferring the first portion of the partially wet composition from thedispenser to the mold may include mechanically transferring the firstportion of the partially wet composition from the dispenser 310 to aconveyance container 330. The first portion may be transferred from thedispenser 310 to a conveyance container 330 using gravitation and/orvibration. The first portion of the partially wet composition may bemechanically transferred from the conveyance container 330 to the mold320. The conveyance container may be used to automatically move portionsof the composition from the dispenser to the mold along tracks, etc.

In some embodiments, mechanically transferring the first portion of thepartially wet composition from the conveyance container to the mold mayinclude moving the conveyance container back and forth above the moldwhile transferring the first portion. In some embodiments, mechanicallytransferring the first portion of the partially wet composition from theconveyance container to the mold may include screeding at least someexcess first portion above an upper level of the open mold using theconveyance container. In some embodiments, mechanically transferring thefirst portion of the partially wet composition from the conveyancecontainer to the mold may include vibrating the conveyance containerwhile transferring the first portion. In some embodiments, a vibrationtable sits below the mold. The mold may be clamped down on top of acarrier (e.g., a production pallet) positioned on the vibration tableduring the fill and/or compression stage. In some embodiments, thevibration may be directed to the mold but transfers to the conveyancecontainer since they are in direct contact with each other. Theconveyance container (and in some embodiments the mold) may be vibratedat between about 35 Hz to 42 Hz or about 35 Hz to 60 Hz (e.g., 38 Hzrunning at 50% power (11 kW, approximately 15 HP) (e.g., using machinesettings)) while transferring the first portion. In some embodiments,the conveyance container (and in some embodiments the mold) may bevibrated at 38 Hz running at 50% power (11 kW, approximately 15 HP(e.g., using machine settings)), based upon machinespecifications/settings actual readings may vary. In some embodiments,the first portion may be transferred by moving the conveyance containerback and forth while vibrating the conveyance container. The mold may befilled for about 2 to 20 seconds, about 4 to 15 seconds, or about 7 to 9seconds (e.g., 8 seconds).

When transferring a partially wet composition with more than 50% closedcell foam particles to a mold the composition tends to just form a moundin the mold and not fill the mold spaces and as such vibration of themold assists in spreading out the composition evenly in the mold.Similar systems may have been used to produce pavers; however pavers areformed from a far denser material such as concrete which may have ahigher water content such that gravity works well enough to fill a moldevenly and vibration is not needed.

In some embodiments, the first portion of the partially wet compositionmay be compressed in the mold. The first portion of the partially wetcomposition may be compressed in the mold to about 60-90% or about80-90% (e.g., 87%) of the first portions initial volume. In someembodiments, one or more tampers 340 may be used to compress the firstportion of the partially wet composition in the mold. In someembodiments, one or more vibrators 350 (e.g., vibration table) may beused to consolidate the first portion of the partially wet compositionin the mold. The mold itself may be vibrated. The first portion may becompressed/consolidated in the mold for a period of time (e.g., about 1to 20 seconds, about 1 to 10 seconds, 3 to 8 seconds, or 4 to 6seconds). The mold may be vibrated during compression at about 50 to 60Hz (e.g., 55 Hz at 60% power (13.2 kW, approximately 18 HP) (e.g., usingmachine settings)). In some embodiments, the mold may be vibrated duringcompression at 55 Hz at 60% power (13.2 kW, approximately 18 HP (e.g.,using machine settings)), based upon machine specifications/settings,actual readings may vary. The first portion may becompressed/consolidated in the mold using tampers 340 and vibrators 350simultaneously. In some embodiments, frequency and/or accelerationranges may be essential for producing a building form including closedcell foam particles. In some embodiments, a system may include a corepuller 360.

In some embodiments, the first portion of the partially wet compositionmay be mechanically released from the mold. Releasing the first portionmay include turning all vibrators off. In some embodiments, a mold maybe formed from at least three portions. The mold may include a body, acore plate, and one or more tamper heads. The mold body may form thefour sides of the building form and the central full core of thebuilding form. The core plate may form a bottom shoulder and bottom halfchannels or half cores. The tamper head may form a top shoulder and tophalf channels or half cores. The mold may be mechanically lifted aportion of a height of the first portion (e.g., <10 mm, <5 mm, or about1 mm). A core plate may be pulled away from the first portion. In someembodiments, the mold may be quickly (e.g., instantaneously) lifted awayfrom the molded first portion. The tampers may remain in position (i.e.,adjacent an upper surface of the molded first portion) while the mold islifted away. After removing the mold the tampers may be removed fromcontacting the upper surface of the molded first portion. In someembodiments, mechanically releasing the first portion of the partiallywet composition from the mold comprises releasing the first portion fromthe mold in less than 2 minutes, less than 1 minute, less than 30seconds, or less than 10 seconds. As mentioned the building form must beproperly formed in the mold, including, but not limited to beingproperly compressed and consolidated as well as have a properconsistency (as based as least in part upon the ratio of water tocementitious material to closed cell foam particles) such that thebuilding form may be released from the mold quickly and in an uncuredstate. Being able to remove the uncured building form from the moldquickly is a major contributing factor for allowing a system to besubstantially automated vastly improving the efficiency of themanufacturing process of building forms over current methods.

FIGS. 4A-B depicts two tables (i.e., TABLE 4a and TABLE 4b) showingpoints along the upper and lower vibration boundaries for systems and/ormethods of preparing building forms.

FIG. 5 depicts a graphical representation of the operational boundariesof vibration for systems and/or methods of preparing building formsexpressed as log-amplitude (root-mean-square (rms) velocity in mm/s)verses frequency (Hz). The upper boundary as depicted in FIG. 5 by line500 is a piecewise linear function connecting the points in Table 4a ofFIG. 4A. The lower boundary as depicted in FIG. 5 by line 510 is apiecewise linear function connecting the points in Table 4b of FIG. 4B.

In some embodiments, the method may include providing a partially wetcomposition in a mold while vibrating the mold, the partially wetcomposition, or both. The method may include transferring the partiallywet composition to the mold while vibrating the mold, the partially wetcomposition, or both. The method may include compressing the partiallywet composition in the mold while vibrating the mold, the partially wetcomposition, or both.

In some embodiments, making the building form may include vibration witha log-amplitude and frequency between a first boundary and a secondboundary. In some embodiments, the first and the second boundaries maybe described as piecewise linear functions connecting the points. Insome embodiments, the first boundary may include a log-amplitude ofabout 200 mm/s at 0 Hz frequency, about 200 mm/s at 20 Hz frequency,about 200 mm/s at 30 Hz frequency, about 25 mm/s at 150 Hz frequency,about 2.0 mm/s at 350 Hz frequency, and about 1.0 mm/s at 600 Hzfrequency. The second boundary may include a log-amplitude of about 0.1mm/s at 0 Hz frequency, about 0.1 mm/s at 20 Hz frequency, about 5.0mm/s at 50 Hz frequency, about 0.5 mm/s at 150 Hz frequency, about 0.1mm/s at 400 Hz frequency, and about 0.1 mm/s at 600 Hz frequency.

In some embodiments, making the building form may include vibration witha log-amplitude and frequency from between about 200 mm/s to about 0.1mm/s at 0 Hz frequency. Making the building form may include vibrationwith a log-amplitude from between about 200 mm/s to about 0.1 mm/s at 20Hz frequency. Making the building form may include vibration with alog-amplitude from between about 200.0 mm/s at 30 Hz frequency to about5.0 mm/s at 50 Hz frequency. Making the building form may includevibration with a log-amplitude from between about 25 mm/s to about 0.5mm/s at 150 Hz frequency. Making the building form may include vibrationwith a log-amplitude from between about 2.0 mm/s at 350 Hz frequency toabout 0.1 mm/s at 400 Hz frequency. Making the building form may includevibration with a log-amplitude from between about 1.0 mm/s to about 0.1mm/s at 600 Hz frequency.

After releasing the molded first portion of the partially wetcomposition, the building form may be removed from the system on aproduction pallet and subsequently stored in a curing room. The moldedbuilding form may be cured for at least 48 hours or for at least 24hours. In some embodiments, the cured building form may have a densityof 21 to 24 lb/ft³ (pcf). In some embodiments, the cured building formmay have a density of 17 to 35 lb/ft³. In some embodiments, the curedbuilding form may have a 7-day compression strength of <40 psi. In someembodiments, the cured building form may have a 7-day compressionstrength of up to 60 psi or up to 100 psi.

In some embodiments, the system may mechanically transfer a secondportion of the partially wet composition from the dispenser to the moldto form the second portion into the desired shape using the same moldinstead of leaving the uncured building form in the mold for hours, daysor even more to cure before removing the cured building form from themold. Embodiments of the system described herein may only use a singlemold or single set of molds (e.g., when more than one building form ismanufactured at a time). As such a single mold or single set of moldsmay be used repeatedly by the system over a relatively short period oftime to produce many building forms in a single day.

EXPERIMENTALS

I. Methods (for Collecting Vibrational Characteristics Expressed asLog-Amplitude Vs. Frequency):

Purpose:

The purpose of testing was to gather the range of vibrationcharacteristics of the block machine mold.

Materials:

A velocimeter (Wilcoxon 783V) was attached using a magnetic base to themold near a corner rib for maximum stiffness. The output of thevelocimeter was routed to a National Instruments USB-9234 dataacquisition D/A converter, then to Nelson Acoustics' TridentMultichannel Realtime Analyzer v6.11. The sensitivity of the transducerwas checked via calibrator and found to be within 5% of its nominalvalue.

Methods:

Spectral data were determined by performing a narrowband analysis at 1Hz resolution, with results in power spectral density using a Harmingwindow. Because the Harming window spreads tonal energy in the frequencyspectrum, we summed the energy in 5 adjacent lines centered on the first8 drive harmonics, plus subharmonics ½, and in a few cases ⅓ and ⅔ aswell. This process mathematically filters out incoherent vibrations atfrequencies not associated with the drive. An 8×6 test matrix was agreedupon which included all combinations of: machine setting frequencies 30,35, 40, 45, 50, 55 and 60 Hz and machine setting power levels 30, 40,50, 60, 70, 80 percent. An extra element was added for the mold filloperation at machine settings of 38 Hz and 55 percent power. Thecompaction operation was described as a machine setting of 55 Hz and 70percent power which is already part of the matrix.

Data:

Data was collected at each determined point and recorded into the NelsonAcoustics' Trident Multichannel Realtime Analyzer v6.11. Vibrationsignals were filtered in post-processing to highlight the relevantharmonics and subharmonics and suppress all other frequencies.

Results:

The results appear to be best expressed in “scatter plots” which relatevibration frequency to log-amplitude. It should be noted that a drivefrequency of X Hz produces vibrations at X but also at nX where n refersto all positive integers. At high levels, fractional values of n(subharmonics) arise. The envelope of each overall signal was determinedas a function of time: the time-weighted linear average velocity isreported. TABLE 4a in FIG. 4 depicts points along the upper bounds ofthe results in the scatter plots. TABLE 4b in FIG. 4 depicts pointsalong the lower bounds of the results in the scatter plots. FIG. 5depicts the upper and lower bounds as piecewise linear functionsconnecting the points depicted in TABLE 4a and TABLE 4b.

In this patent, certain U.S. patents, U.S. patent applications, andother materials (e.g., articles) have been incorporated by reference.The text of such U.S. patents, U.S. patent applications, and othermaterials is, however, only incorporated by reference to the extent thatno conflict exists between such text and the other statements anddrawings set forth herein. In the event of such conflict, then any suchconflicting text in such incorporated by reference U.S. patents, U.S.patent applications, and other materials is specifically notincorporated by reference in this patent.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only and is for the purpose of teaching those skilled inthe art the general manner of carrying out the invention. It is to beunderstood that the forms of the invention shown and described hereinare to be taken as the presently preferred embodiments. Elements andmaterials may be substituted for those illustrated and described herein,parts and processes may be reversed, and certain features of theinvention may be utilized independently, all as would be apparent to oneskilled in the art after having the benefit of this description of theinvention. Changes may be made in the elements described herein withoutdeparting from the spirit and scope of the invention as described in thefollowing claims.

What is claimed is:
 1. A method for preparing building forms includingat least some cementitious materials, comprising: combining drycementitious material particles with closed cell foam particles to forma dry composition; mixing the dry composition such that at least some ofthe cementitious material particles adhere to at least some surfacedeformations on the surface of the closed cell foam particles, andwherein the closed cell foam particles comprise a closed cell foamstructure; mixing water with the dry composition to form a wetcomposition; containing the wet composition in a dispenser, wherein thedispenser forms at least a portion of a substantially automated buildingform production system; mechanically transferring a first portion of thewet composition from the dispenser to a mold coupled to the dispenser toform the first portion into a desired shape; vibrating the mold using avibrator; and consolidating the first portion of the wet composition inthe mold using the vibrator; wherein vibrating comprises vibration witha log-amplitude between a first boundary and a second boundary, whereinthe first boundary comprises a first piecewise linear function definedby linear line segments extending between a first set of pointscomprising a log-amplitude of about 200 mm/s at 0 Hz frequency, about200 mm/s at 20 Hz frequency, about 200 mm/s at 30 Hz frequency, about 25mm/s at 150 Hz frequency, about 2.0 mm/s at 350 Hz frequency, and about1.0 mm/s at 600 Hz frequency, and wherein the second boundary comprisesa second piecewise linear function defined by linear line segmentsextending between a second set of points comprising a log-amplitude ofabout 0.1 mm/s at 0 Hz frequency, about 0.1 mm/s at 20 Hz frequency,about 5.0 mm/s at 50 Hz frequency, about 0.5 mm/s at 150 Hz frequency,about 0.1 mm/s at 400 Hz frequency, and about 0.1 mm/s at 600 Hzfrequency; mechanically releasing the first portion of the wetcomposition from the mold; mechanically transferring a second portion ofthe wet composition from the dispenser to the mold to form the secondportion into the desired shape; mechanically releasing the secondportion of the wet composition from the mold; and curing the firstportion and the second portion of the wet composition after mechanicallyreleasing from the mold to form s-building forms including at least somecementitious materials, wherein the building form comprises a density of17 to 35 lb/ft³.
 2. The method of claim 1, wherein the building formcomprises a reduced weight composite building form.
 3. The method ofclaim 1, wherein the cementitious materials comprise cement and fly ash.4. The method of claim 1, wherein the closed cell foam particlescomprise expanded polystyrene.
 5. The method of claim 1, furthercomprising compressing the first portion of the wet composition in themold.
 6. The method of claim 1, further comprising compressing the firstportion of the wet composition in the mold to about 60-90% of the firstportions initial volume.
 7. The method of claim 1, further comprisingcompressing the first portion of the wet composition in the mold toabout 80-90% of the first portions initial volume.
 8. The method ofclaim 1, further comprising compressing the first portion of the wetcomposition in the mold using a tamper and a vibrator.
 9. The method ofclaim 1, further comprising compressing the first portion of the wetcomposition in the mold using a tamper and a vibrator for a period oftime, wherein the period of time is about 1 to 20 seconds, 3 to 8seconds, or 4 to 6 seconds.
 10. The method of claim 1, furthercomprising: vibrating the mold using a vibrator; and consolidating thefirst portion of the wet composition in the mold using the vibrator. 11.The method of claim 1, wherein mechanically transferring the firstportion of the wet composition from the dispenser to the mold comprises:mechanically transferring the first portion of the wet composition fromthe dispenser to a conveyance container; and mechanically transferringthe first portion of the wet composition from the conveyance containerto the mold.
 12. The method of claim 11, wherein mechanicallytransferring the first portion of the wet composition from theconveyance container to the mold comprises vibrating the conveyancecontainer and mechanically agitating the material within the containerwhile transferring the first portion.
 13. The method of claim 11,wherein mechanically transferring the first portion of the wetcomposition from the conveyance container to the mold comprisesvibrating the conveyance container while transferring the first portion,wherein vibrating comprises vibration with a log-amplitude between afirst boundary and a second boundary, wherein the first boundarycomprises a first piecewise linear function defined by linear linesegments extending between a first set of points comprising alog-amplitude of about 200 mm/s at 0 Hz frequency, about 200 mm/s at 20Hz frequency, about 200 mm/s at 30 Hz frequency, about 25 mm/s at 150 Hzfrequency, about 2.0 mm/s at 350 Hz frequency, and about 1.0 mm/s at 600Hz frequency, and wherein the second boundary comprises a secondpiecewise linear function defined by linear line segments extendingbetween a second set of points comprising a log-amplitude of about 0.1mm/s at 0 Hz frequency, about 0.1 mm/s at 20 Hz frequency, about 5.0mm/s at 50 Hz frequency, about 0.5 mm/s at 150 Hz frequency, about 0.1mm/s at 400 Hz frequency, and about 0.1 mm/s at 600 Hz frequency. 14.The method of claim 1, wherein mechanically releasing the first portionof the wet composition from the mold comprises releasing the firstportion from the mold in less than 2 minutes, less than 1 minute, lessthan 30 seconds, or less than 10 seconds.
 15. The method of claim 1,wherein the building form comprises a 7-day compression strength of upto 100 psi.
 16. A method for preparing building forms including at leastsome cementitious materials, comprising: automatically combining drycementitious material particles with closed cell foam particles to forma dry composition; automatically mixing the dry composition such that atleast some of the cementitious material particles adhere to at leastsome surface deformations on the surface of the closed cell foamparticles, and wherein the closed cell foam particles comprise a closedcell foam structure; automatically mixing water with the dry compositionto form a wet composition; containing the wet composition in adispenser, wherein the dispenser forms at least a portion of asubstantially automated building form production system; mechanicallytransferring, in an automated fashion, a first portion of the wetcomposition from the dispenser to a mold coupled to the dispenser toform the first portion into a desired shape; compressing the firstportion of the wet composition in the mold to about 80-90% of the firstportions initial volume; mechanically releasing, in an automatedfashion, the first portion of the wet composition from the mold afterless than two minutes after transferring the first portion of the wetcomposition from the dispenser to the mold; mechanically transferring,in an automated fashion, a second portion of the wet composition fromthe dispenser to the mold to form the second portion into the desiredshape; mechanically releasing, in an automated fashion, the secondportion of the wet composition from the mold after less than two minutesafter transferring the second portion of the wet composition from thedispenser to the mold; and curing the first portion and the secondportion of the wet composition after mechanically releasing from themold to form a building form including at least some cementitiousmaterials, wherein the building form comprises a density of 17 to 35lb/ft³.
 17. The method of claim 16, further comprising compressing thefirst portion of the wet composition in the mold using a tamper and avibrator for a period of time, wherein the period of time is about 1 to20 seconds, 3 to 8 seconds, or 4 to 6 seconds.
 18. The method of claim16, further comprising: vibrating the mold using a vibrator; andconsolidating the first portion of the wet composition in the mold usingthe vibrator.
 19. The method of claim 16, further comprising: vibratingthe mold using a vibrator; and consolidating the first portion of thewet composition in the mold using the vibrator; wherein vibratingcomprises vibration with a log-amplitude between a first boundary and asecond boundary, wherein the first boundary comprises a first piecewiselinear function defined by linear line segments extending between afirst set of points comprising a log-amplitude of about 200 mm/s at 0 Hzfrequency, about 200 mm/s at 20 Hz frequency, about 200 mm/s at 30 Hzfrequency, about 25 mm/s at 150 Hz frequency, about 2.0 mm/s at 350 Hzfrequency, and about 1.0 mm/s at 600 Hz frequency, and wherein thesecond boundary comprises a second piecewise linear function defined bylinear line segments extending between a second set of points comprisinga log-amplitude of about 0.1 mm/s at 0 Hz frequency, about 0.1 mm/s at20 Hz frequency, about 5.0 mm/s at 50 Hz frequency, about 0.5 mm/s at150 Hz frequency, about 0.1 mm/s at 400 Hz frequency, and about 0.1 mm/sat 600 Hz frequency.
 20. The method of claim 16, wherein mechanicallytransferring the first portion of the wet composition from the dispenserto the mold comprises: mechanically transferring the first portion ofthe wet composition from the dispenser to a conveyance container; andmechanically transferring the first portion of the wet composition fromthe conveyance container to the mold.
 21. The method of claim 20,wherein mechanically transferring the first portion of the wetcomposition from the conveyance container to the mold comprisesvibrating the conveyance container and mechanically agitating thematerial within the container while transferring the first portion. 22.The method of claim 20, wherein mechanically transferring the firstportion of the wet composition from the conveyance container to the moldcomprises vibrating the conveyance container while transferring thefirst portion, wherein vibrating comprises vibration with alog-amplitude between a first boundary and a second boundary, whereinthe first boundary comprises a first piecewise linear function definedby linear line segments extending between a first set of pointscomprising a log-amplitude of about 200 mm/s at 0 Hz frequency, about200 mm/s at 20 Hz frequency, about 200 mm/s at 30 Hz frequency, about 25mm/s at 150 Hz frequency, about 2.0 mm/s at 350 Hz frequency, and about1.0 mm/s at 600 Hz frequency, and wherein the second boundary comprisesa second piecewise linear function defined by linear line segmentsextending between a second set of points comprising a log-amplitude ofabout 0.1 mm/s at 0 Hz frequency, about 0.1 mm/s at 20 Hz frequency,about 5.0 mm/s at 50 Hz frequency, about 0.5 mm/s at 150 Hz frequency,about 0.1 mm/s at 400 Hz frequency, and about 0.1 mm/s at 600 Hzfrequency.
 23. The method of claim 16, wherein mechanically releasingthe first portion of the wet composition from the mold comprisesreleasing the first portion from the mold in less than 2 minutes, lessthan 1 minute, less than 30 seconds, or less than 10 seconds.
 24. Themethod of claim 16, wherein the building form comprises a 7-daycompression strength of up to 100 psi.